Turbo-machine component and method

ABSTRACT

A component, a component manufacturing process, and a component operation process are disclosed. The component has a diffuser permitting compressible fluid to flow throughout a first region and a second region of the diffuser at a decreasing velocity. The diffuser includes a coating collection feature. The component manufacturing process includes positioning the component and applying the coating to at least a surface of the component outside of the diffuser and to at least a portion of the second region, not to the first region, to the coating collection feature, or a combination thereof. The component operation process includes positioning the component and transporting the compressible fluid through the diffuser.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

The United States Government retains license rights in this invention and the right in limited circumstances to require the patent owner to license others on reasonable terms by the terms of Government Contract No. 9FB-05 awarded by the United Stated Department of Energy.

FIELD OF THE INVENTION

The present invention is directed to components, processes of manufacturing components, and processes of operating components. More specifically, the present invention relates to components and processes involving diffusers.

BACKGROUND OF THE INVENTION

Diffusers permit airflow to and from systems relying upon air flow. For example, diffusers cool components or portions of components subjected to high temperature due to operation of the component, the environment of the component, or combinations thereof. For example, diffusers in turbine blades cool the blades, which operate under extreme temperatures during power generation and/or thrust generation. Diffusers in nozzles cool portions of nozzles proximal to flame regions and/or provide air to the flame region, thereby assisting with combustion.

These diffusers and other known diffusers facilitate expansion of compressible fluids and/or provide cooling in other systems by reducing airflow velocity by having a cross-sectional area at a diffuser exit that is larger than a cross-sectional area at a diffuser entrance. As the cross-sectional area increases, the velocity of the flow decreases, thereby lowering pressure of the flow. At the exit, the diffuser can be open to another component, such as a compressor, a flame region, a pressure side of a blade, or any other suitable component or environment.

Generally, the cross-sectional areas of diffusers increase at constant rates. Such constant rate increases permit the velocity to decrease at a constant rate or an increasing rate. For example, known diffusers generally have a geometry that is either partially conical, curvilinear, stepped, and/or partially tubular. Such geometries facilitate a decrease in velocity.

Clogging of diffusers can modify the internal profile of the diffuser, thereby modifying the velocity profile of the diffuser. Prior attempts to use coatings on surfaces outside of diffusers but still proximal to the diffusers have resulted in such clogging or otherwise modifying of the internal profiles of the diffusers. For example, such attempts resulted in constrictions of flow-paths within diffusers, thereby undesirably increasing velocity through certain portions within the diffuser. Such modifications to the rate of fluid flow within the diffusers could result in operational inefficiencies, inadequate fluid transport, or failure of a part.

A component, a component manufacturing process, and a component operation process that do not suffer from one or more of the above drawbacks would be desirable in the art.

BRIEF DESCRIPTION OF THE INVENTION

In an exemplary embodiment, a component has a diffuser that includes a first region having a first section with a first cross-sectional area, a second region having a second section with a second cross-sectional area that is greater than the first cross-sectional area, a coating collection feature at least partially positioned within the second region, and a flow-path arranged and disposed to permit compressible fluid to flow throughout the first region and the second region of the diffuser at a decreasing velocity.

In another exemplary embodiment, a component-manufacturing process includes positioning the component and applying a coating to at least a surface of the component outside of the diffuser and to at least a portion of the second region, not to the first region, to the coating collection feature, or a combination thereof. The component has a diffuser including a first region having a first section with a first cross-sectional area, a second region having a second section with a second cross-sectional area that is greater than the first cross-sectional area, a coating collection feature at least partially positioned within the second region, and a flow-path arranged and disposed to permit compressible fluid to flow throughout the first region and the second region of the diffuser at a decreasing velocity.

In another exemplary embodiment, a component operation process includes positioning the component and transporting a compressible fluid through a diffuser. The component has a diffuser including a first region having a first section with a first cross-sectional area, a second region having a second section with a second cross-sectional area that is greater than the first cross-sectional area, a coating collection feature at least partially positioned within the second region, and a flow-path arranged and disposed to permit compressible fluid to flow throughout the first region and the second region of the diffuser at a decreasing velocity.

Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a schematic sectional view of an exemplary component without a coating according to the disclosure.

FIG. 2 shows a schematic sectional view of an exemplary component with a coating according to the disclosure.

FIG. 3 shows a schematic sectional view of an exemplary coated component with a linear coating collection feature according to the disclosure.

FIG. 4 shows a schematic sectional view of an exemplary coated component with a curved coating collection feature according to the disclosure.

FIG. 5 shows a schematic sectional view of an exemplary coated component according to the disclosure.

FIG. 6 shows a schematic sectional view of an exemplary coated component according to the disclosure.

FIG. 7 shows a schematic sectional view of an exemplary component with a coating applied at an angled orientation according to an exemplary process of the disclosure.

FIG. 8 shows a schematic sectional view of an exemplary component having coating on a surface exterior to a diffuser but not on the diffuser according to the disclosure.

FIG. 9 shows a schematic view of an exemplary component being a turbine blade according to the disclosure.

FIG. 10 shows a schematic view of an exemplary component being a nozzle according to the disclosure.

Wherever possible, the same reference numbers will be used throughout the drawings to represent the same parts.

DETAILED DESCRIPTION OF THE INVENTION

Provided is an exemplary component, a component manufacturing process, and a component operation process. Embodiments of the present disclosure permit airflow for cooling components, reduce or eliminate partial or complete blockages of diffusers, permit operation in more harsh environments (for example, environments having greater thermal gradients), permit additional control of fluid flow-paths and/or fluid velocity profiles within diffusers, facilitate a controlled decrease in velocity of compressible fluids within diffusers, increase operational efficiencies, or combinations thereof.

FIG. 1 shows a portion of a component 100 according to an embodiment of the disclosure. The component 100 is any suitable article for transport of a fluid. For example, in one embodiment, the component 100 is a turbine component, such as, a turbine blade 902 (see FIG. 9), a nozzle 910 (see FIG. 10), or any other article containing one or more diffusers 102 for transporting a fluid, such as a compressible fluid, along a predetermined flow-path 114.

Generally, the diffuser 102 is any suitable geometry. In one embodiment, portions of the diffuser 102 include a cylindrical geometry, a tapered geometry, a partially conical geometry, a curvilinear geometry, a complex geometry, or any other geometry with an expanding cross-sectional area through a portion of the diffuser 102 or throughout the diffuser 102. The size, position, and shape of the diffuser 102 corresponds to the component 100 including the diffuser 102, the amount of the diffusers 102 included in the component 100, the proximity between the diffusers 102 used in the component 100, the amount of cooling and/or other fluid transport to be performed by the diffusers 102, manufacturing technologies employed in forming the diffusers 102, or combinations thereof.

The diffuser 102 includes any suitable number of regions, for example, two regions, three regions, four regions, five regions, six regions, or more. In one embodiment, the diffuser 102 has a first region 104 and a second region 106. The first region 104 has a first section 111 with a first cross-sectional area. Overall, the first region 104 includes constant cross-sectional areas or increasing cross-sectional areas. The second region 106 has a second section 113 with a second cross-sectional area. Overall, the second region 106 includes constant cross-sectional areas or increasing cross-sectional areas. The second cross-sectional area in the second section 113 is greater than the first cross-sectional area in the first section 111, thereby permitting a decrease in velocity of the compressible fluid from between the first section 111 and the second section 113, between the first region 104 and the second region 106, otherwise along the flow-path 114, or combinations thereof.

In one embodiment, the diffuser 102 further includes a third region 108 between the first region 104 and the second region 106. In this embodiment, the third region 108 is oriented at a predetermined angle 109 in comparison to the first region 104, for example, between about 1 degree and about 5 degrees, between about 1 degree and about 10 degrees, between about 5 degrees and about 10 degrees, between about 10 degrees and about 20 degrees, about 1 degree, about 5 degrees, about 10 degrees, about 15 degrees, about 20 degrees, or any suitable combination or sub-combination thereof.

The flow-path 114 of the diffuser 102 extends through the first region 104, the second region 106, and any other regions of the diffuser 102, for example, the third region 108. The flow-path 114 abuts all or a portion of one or more of the first region 104, the second region 106, the third region 108, the coating collection feature 112, and a portion or all surfaces of a coating 202 (see FIG. 2) in the diffuser 102.

The diffuser 102 includes the coating collection feature 112. The coating collection feature 112 prevents the coating 202 from travelling into undesired portions of the diffuser 102 (such as the first region 104) and/or maintains the coating 202 in desired portions (such as the second region 106). For example, in one embodiment, the coating collection feature 112 prevents a portion or all of the coating 202 from travelling into the first region 104 and/or the third region 108 of the diffuser 102 during application of the coating 202. In another embodiment, in addition to regions outside of the diffuser 102, a portion or all of the coating 202 is maintained in the second region 106 of the diffuser 102 by the coating collection feature 112.

In one embodiment, the coating collection feature 112 is at least partially positioned within the second region 106, between the second region 106 and the first region 102, between the second region 106 and the third region 108, or a combination thereof. The coating collection feature 112 includes a geometry controlling the travelling of the coating 202. In one embodiment, as shown in FIGS. 1-2, the geometry is an angled recess 116. The angled recess 116 widens the diffuser 102 along the flow-path 114, thereby decreasing velocity of the compressible fluid traveling along the flow-path 114.

The diffuser 102 controls the velocity of the compressible fluid flowing through the diffuser 102, an amount of cooling of the component 100 facilitated by the diffuser 102, an amount of the compressible fluid transported, or combinations thereof. In one embodiment, the flow-path 114 of the diffuser 102 is arranged and disposed to permit the compressible fluid to flow throughout the first region 104 and the second region 106 of the diffuser 102 at a decreasing velocity. In a further embodiment, the flow-path 114 is arranged and disposed to permit the compressible fluid to flow throughout the diffuser 102 at the decreasing velocity. In one embodiment, the flow-path 114 is arranged and disposed to permit the compressible fluid to decrease velocity at a predetermined rate, for example, a substantially constant rate or an increasing rate.

Referring to FIG. 2, in one embodiment, the diffuser 102 includes a coating 202, such as a thermal barrier coating, for example, a coating having yttria-stabilized zirconia, ytterbium zirconium, fully-stabilized gadolinia zirconia, alumina, pyrochlores, or combinations thereof. In a further embodiment, the coating 202 further includes a bonding layer, for example, a MCrAlY alloy (where M identifies one or more of Fe, Ni, and Co), intermetallic aluminide, or any other suitable material. The coating 202 is applied to the diffuser 102 by any suitable process, for example, physical vapor deposition, chemical vapor deposition, cold spray, or a combination thereof.

The coating collection feature 112 is positioned and oriented to prevent the coating 202 and/or other debris from disrupting the flow-path 114 and/or a predetermined velocity profile of the diffuser 102. FIGS. 1-5 show embodiments with a portion or all of the coating collection feature 112 positioned substantially directly below an upper surface 118 of the component 100. FIGS. 6-8 show embodiments with a portion or all of the coating collection feature 112 not covered by the upper surface 118.

FIG. 3 shows an embodiment with the coating collection feature 112 completely covered by the upper surface 118. In this embodiment, the coating 202 is substantially or entirely prevented from flowing into the first region 104, but the coating 202 is inconsistent in thickness within the second region 106, which may impact the flow-path 114, for example, by causing the decrease in velocity of the compressible fluid to be slowed or partially reversed.

FIG. 4 shows an embodiment with the coating collection feature 112 completely covered by the upper surface 118. In this embodiment, the coating collection feature 112 tapers or curves from the first region 104, thereby substantially or entirely preventing the coating 202 from flowing into the first region 104. In this embodiment, the thickness of the coating 202 in the second region is more consistent than the embodiment shown in FIG. 3, but a coating thickness 208 that can be applied without the coating 202 entering the first region 104 is lower than the coating thickness of the embodiment of FIG. 3.

FIG. 5 shows an embodiment with the coating collection feature 112 defining a large bored out portion 502 forming the second region 106. In the embodiment shown in FIG. 5, the coating collection feature 112 is completely covered by the upper surface 118. In this embodiment, the coating 202 fills the second region 106 and the flow-path 114 substantially decreases velocity of the compressible fluid. In a further embodiment, the coating 202 is applied at a greater thickness, thereby modifying the amount of the decrease in the velocity of the compressible fluid along the flow-path 114. The embodiment shown in FIG. 6 shows the coating collection feature 112 with a similar geometry but not covered by the upper surface 118. The coating 202 in the second region 106 slightly decreases the velocity of the compressible fluid along the flow-path 114.

FIG. 7 shows an embodiment with the coating collection feature 112 completely uncovered relative to the upper surface 118. FIG. 8 shows an embodiment with the coating collection feature 112 being aligned with the edge of the upper surface 118. In one embodiment, the portions of the component 100 and/or the diffuser that are coated are based upon the application technique employed. For example, referring to FIG. 7, in one embodiment, the coating 202 is applied at an angled orientation 702. The angled orientation 702 substantially or entirely prevents the coating 202 from being applied to the first region 104. In one embodiment, the angled orientation 702 is parallel with and/or in line with a portion or all of the angled recess 116. Additionally or alternatively, referring to FIG. 8, in one embodiment, the coating 202 is selectively applied to predetermined portions of the component 100, such as the surface 206. In this embodiment, only portions of the second region 106 include the coating 202 and the coating 202 thickness is inconsistent.

The orientation of the coating collection feature 112 is based upon the geometry of the coating collection feature 112. For example, in one embodiment, as shown in FIGS. 1-2, the coating collection feature 112 includes a linear geometry. In one embodiment, the coating collection feature 112 is oriented at a predetermined coating collection feature angle 115 in comparison to the first region 104 or the second region 106, for example, between about 10 degrees and about 150 degrees, between about 10 degrees and about 90 degrees, between about 10 degrees and about 45 degrees, between about 10 degrees and about 30 degrees, between about 30 degrees and about 90 degrees, between about 30 degrees and about 60 degrees, between about 30 degrees and about 45 degrees, between about 45 degrees and about 60 degrees, between about 45 degrees and about 90 degrees between about 60 degrees and about 90 degrees, between about 60 degrees and about 150 degrees, between about 90 degrees and about 150 degrees, about 90 degrees (as shown in FIGS. 1-2, 7, and 8), about 120 degrees (as shown in FIGS. 3, 5, and 6), about 60 degrees, about 30 degrees, about 10 degrees, or any suitable combination or sub-combination thereof.

In one embodiment, the coating 202 is applied in a predetermined portion of the diffuser 102. For example, in one embodiment, the coating 202 is at least partially or fully within the second region 106, at least partially or fully in contact with the coating collection feature 112, or a combination thereof. In one embodiment, the coating 202 abuts the flow-path 114 and/or an uncoated portion 204 of the second region 106 abuts the flow-path 114. In a further embodiment, the coating 202 is at least partially positioned on a surface 206 of the component 100 outside the diffuser 102.

The coating 202 is applied at a predetermined thickness, such as the thickness 208. Suitable thickness include, but are not limited to, at least about 5 mils, at least about 10 mils, at least about 20 mils, at least about 30 mils, between about 5 mils and about 30 mils, between about 10 mils and about 30 mils, between about 20 mils and about 30 mils, between about 10 mils and about 20 mils, between about 5 mils, or any suitable combination or sub-combination thereof.

In one embodiment, the coating 202 is applied by positioning the component 100 and applying the coating 202 to at least a surface, such as the surface 206 outside of the diffuser 102 of the component 100. In this embodiment, the coating 202 is also applied to at least a portion of the second region 106, does not contact the first region 104, contacts the coating collection feature 112, or a combination thereof. The portions of the diffuser 102 that are coated or remain uncoated correspond to the application technique, the thickness of the coating 202 applied, the geometry of the coating collection feature 112, the configuration of the second region 106, or combinations thereof.

In one embodiment, the compressible fluid is transported along the flow-path 114 through the diffuser 102. For example, referring to FIG. 9, in one embodiment, the compressible fluid is air and the component 100 is a turbine blade 902. The diffusers 102 are positioned along any portion of the turbine blade 902, for example, on or proximal to a pressure side 904, on or proximal to a leading edge 906, on or proximal to a trailing edge 908, on or proximal to any other portion of the turbine blade 902 that benefits from cooling, or a combination thereof. In this embodiment, the properties of the coating 202 permit operation of the turbine blade 902 with a greater temperature gradient and/or greater fatigue resistance.

Referring to FIG. 10, in one embodiment, the compressible fluid is air and the component 100 is a nozzle 910. The diffusers 102 are positioned in any portion of the nozzle 910, for example, around a flame region 912 or any region that benefits from cooling. In this embodiment, the properties of the coating 202 permit operation of the nozzle 910 with a greater temperature gradient and/or greater fatigue resistance.

While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. 

What is claimed is:
 1. A component having a diffuser, the diffuser comprising: a first region having a first section with a first cross-sectional area; a second region having a second section with a second cross-sectional area that is greater than the first cross-sectional area; a coating collection feature at least partially positioned within the second region; and a flow-path arranged and disposed to permit compressible fluid to flow throughout the first region and the second region of the diffuser at a decreasing velocity.
 2. The component of claim 1, further comprising a coating at least partially within the second region.
 3. The component of claim 2, wherein the coating is a thermal-barrier coating.
 4. The component of claim 2, wherein the coating abuts the flow-path.
 5. The component of claim 2, wherein an uncoated portion of the second region abuts the flow-path.
 6. The component of claim 2, wherein the coating is at least partially positioned on a surface of the component outside the diffuser.
 7. The component of claim 6, wherein the portion of the coating on the surface includes a thickness of at least 5 mils.
 8. The component of claim 6, wherein the portion of the coating on the surface includes a thickness of at least 20 mils.
 9. The component of claim 6, wherein the portion of the coating on the surface includes a thickness of at least 30 mils.
 10. The component of claim 1, further comprising a third region having a third section with a third cross-sectional area that is greater than the first cross-sectional area and less than the second cross-sectional area, the third section abutting the flow-path.
 11. The component of claim 1, further comprising a coating in contact with the coating collection feature.
 12. The component of claim 1, wherein the component is a turbine component.
 13. The component of claim 12, wherein the component is a blade and the diffuser is arranged and disposed for air flow.
 14. The component of claim 13, wherein the diffuser is positioned on or proximal to a trailing edge of the blade.
 15. The component of claim 13, wherein the diffuser is positioned on or proximal to a pressure side of the blade.
 16. The component of claim 1, wherein the flow-path in the diffuser is arranged and disposed to permit the compressible fluid to decrease velocity at a substantially constant rate.
 17. The component of claim 1, wherein the flow-path in the diffuser is arranged and disposed to permit the compressible fluid to decrease velocity at an increasing rate.
 18. The component of claim 1, wherein the flow-path is arranged and disposed to permit the compressible fluid to flow throughout the diffuser at the decreasing velocity.
 19. A component manufacturing process, comprising: positioning the component, the component having a diffuser, the diffuser comprising: a first region having a first section with a first cross-sectional area; a second region having a second section with a second cross-sectional area that is greater than the first cross-sectional area; a coating collection feature at least partially positioned within the second region; and a flow-path arranged and disposed to permit compressible fluid to flow throughout the first region and the second region of the diffuser at a decreasing velocity. applying a coating to at least a surface of the component outside of the diffuser and to at least a portion of the second region, not to the first region, to the coating collection feature, or a combination thereof.
 20. A component operation process, the process comprising: positioning the component having a diffuser, the diffuser comprising: a first region having a first section with a first cross-sectional area; a second region having a second section with a second cross-sectional area that is greater than the first cross-sectional area; a coating collection feature at least partially positioned within the second region; and a flow-path arranged and disposed to permit a compressible fluid to flow throughout the first region and the second region of the diffuser at a decreasing velocity; and transporting the compressible fluid through the diffuser. 